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www.akrapovic.com *503203* Installation instructions Akrapovič Exhaust Systems: Slip-On EC type approval & Optional header, Slip-On open & Optional header for the HONDA CBR250R
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  • www.akrapovic.com

    *503203*

    Installation instructions

    Akrapovi Exhaust Systems:Slip-On EC type approval & Optional header,Slip-On open & Optional headerfor theHONDA CBR250R

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    Congratulations on purchasing an Akrapovi exhaust system. Please read the entire installation manual prior to undertaking any activities related to installation of your new Akrapovi exhaust system. In case you do not fully understand the manual or any of its parts, please contact your authorized dealer!

    This product should be installed by someone with sufficient knowledge of exhaust systems and their installation, and appropriate hand or power tools. If you are not qualified for this work, please utilize a certified mechanic for installation. By installing Your Akrapovi exhaust system, you indicate that you have read the installation manual in its entirety and you agree with the terms stated herein.

    It is your responsibility to follow all installation instruction guidelines supplied with the Akrapovi exhaust system and undertake all necessary safety precautions. Akrapovi d.d. assumes no responsibility for damages occurring from misuse, abuse, improper installation, improper operation, lack of responsible care, or all previously stated reasons resulting from incompatibility with other manufacturers products and/or systems.

    IMPORTANT INFORMATION

    Exclusion of Certain Liability1. Themanufacturer,importerordealershallnotbeliableforanyincidentaldamageincludingpersonalinjury

    oranyotherdamagescausedbyimproperinstallationoroperationoftheAkrapoviexhaustsystem.Wheninstalling theAkrapovi exhaust systembe careful that the exhaust systemdoes not touch other partssensitivetohightemperature.

    2. Akrapovimakesnorepresentationorwarrantieswithregardtodamagecausedbytheimproperinstallation,useandmaintenanceoftheAkrapoviexhaustsystem.Thewarrantyislimitedtodefectsrecognizedbyourtechnicaldepartmentandduetonormaluse,andexcludesitemssubjecttonormalwear(gasketsanddampingwool).Theguaranteeisvoidincaseofaccident,modification,improperorcompetitionuse.

    3. Donotattempttoinstall theAkrapoviexhaustsystemonavehiclemodelforwhichitwasnotmadeortestedbyAkrapovi.

    4. Whentheexhaustsystemgetsveryhotduringoperation,becarefulnottoburnyourselfontheexhaustsystemorpartswhichareindirectcontactwithit,evenwhentheengineisnotrunning.Alsoprotectotherpeople,especiallychildren,fromtheinjuriesmentionedabove.

    5. InsomecasesAkrapoviexhaustsystemkitscontainchemicalproducts(ceramicanti-seizinggrease;boltsealant).Handlewithcare,donot inhaleorswallow.Avoidexcessivecontactwithskin,eyesormucousmembranes.Keepoutofreachofchildren.

    6. TechnicalspecificationsofAkrapoviexhaustsystemsandrelatedproductsaresubjecttochangewithoutnotice.

    7. Before removing theoriginalexhaustsystemfromyourvehicle,pleasecompare thepartsyoureceivedwiththelistofmaterialsprovidedintheinstallationmanualinordertoassurethatyouhaveallthepartsnecessaryfortheinstallationofyournewAkrapoviexhaustsystem.

    8. Although thismanualconsistsof instructions for installation inwritten form,aswellasphotographsandpictures representing individual stepsof the installation, pleasenote that thephotographsandpicturesaresymbolicandareintendedforrepresentationofgeneraloverviewonly.Thephotographsandpicturescontainedhereinshouldserveasaguidelineonlyandactual installationoftheexhaustsystemmaynotcorrespondwiththephotographsandpicturesentirely.

    9. Theprocessofuninstallingtheoriginalexhaustsystemmayvarydependingontheexistingexhaustsystem.Pleasefollowtheoriginalexhaustsystemmanufacturersinstructionsforuninstallingtheoriginalexhaustsystem.

    TrademarksTheAkrapoviExhaustSystemTechnologylogoisaregisteredtrademarkofAkrapovid.d.

    Akrapovi websiteInformationaboutAkrapoviexhaustsystemsandrelatedproductsisavailableontheAkrapoviwebsiteat:http://www.akrapovic.com/

    CopyrightNopartoftheAkrapoviexhaustsystemoritsdocumentationmaybereproducedordistributedinanyformorbyanymeanswithoutthepriorwrittenauthorizationoftheAkrapovicompany.

    Akrapovi,d.d.Allrightsreserved.

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    CAUTIONORWARNINGINSTALLATION TIP

    TOOLS REQUIRED TIGHTENING TORQUE

    SymbolsThefollowingsymbolsareusedthroughouttheseinstallationinstructions:

    USE BOLT SEALANT;Apply3to4smalldropsofboltsealantontothecleanedanddegreasedthreadsbeforetighteningthebolts.WARNING! Avoid contact with skin, eyes and mucous membranes. Do not inhale fumes. Keep out of reach of children.

    USE ANTI-SEIZE LEAD-FREE COPPER PASTE(blacktube);Providestrouble-freeandlong-lastingprotectionagainstseizing,corrosionandrustingofbolts,threadedends,nuts,joints,etc.Alsoprotectsagainstvibration,wearandimpact. WARNING! Avoid eye contact. Avoid excessive skin contact. Keep out of reach of children.

    USE ANTI-SEIZING GREASE(whitetube);Preventsseizing,corrosionandexcessivewearbetweenthetitaniumcomponentsofyourexhaustsystem.WARNING! Avoid eye contact. Avoid excessive skin contact. Keep out of reach of children.

    BEFORE INSTALLING, CHECK SCHEMATIC OF THE EXHAUST SYSTEM!

    IF ANY ITEMS IN THE AKRAPOVI EXHAUST SYSTEM PACKAGE ARE MISSING, PLEASE CONTACT YOUR AUTHORIZED DEALER. KEEP THE SCHEMATIC FOR FUTURE REFERENCE.

    THESE INSTALLATION INSTRUCTIONS MUST BE READ CAREFULLY IN ORDER TO ENSURE PROPER INSTALLATION AND OPERATION OF THE AKRAPOVI EXHAUST SYSTEM.

    THE EXHAUST SYSTEM CAN BE EXTREMELY HOT. ALLOW THE EXHAUST AND ENGINE TO COOL DOWN BEFORE BEGINNING INSTALLATION.

    WE ADVISE YOU TO LEAVE INSTALLATION TO A QUALIFIED SERVICEMAN. IMPROPER INSTALLATION MAY RESULT IN A SHORTER LIFETIME OF THE EXHAUST SYSTEM AND/OR DAMAGE TO THE VEHICLE.

    T-handle 12 mm wrenchT-handle 5 mm three hexagon key wrenchT-handle 6 mm three hexagon key wrenchT-handle 12 mm wrench key swiveling wrenchCombination 12 mm wrenchSpring puller

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    Figure 1

    Figure 2

    1.2.

    Putthemotorcycleonasidestand,werecommendaracingstand.Untightenthemarkedlinkpipeclamp,unscrewthemarkedmufflerbracketboltandremovethestockmuffleroff themotorcycle (Figure 1, 2).

    REMOVAL OF ORIGINAL EXHAUST SYSTEM:

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    Figure 3

    Figure 4

    3. For optional Akrapovi header pipe only:unscrewthemarkedboltandpartlyremovetherightlowerpartofthecowling(Figure 3).

    4. For optional Akrapovi header pipe only: unscrewthemarkedoriginalheaderpipebracketbolt(Figure 4).

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    Figure 5

    Figure 6

    5.

    1.

    For optional Akrapovi header pipe only: unscrewthetwomarkednutsandremovethestockheaderpipeoffthemotorcycle(Figure 5).

    INSTALLATION OF THE AKRAPOVI EXHAUST SYSTEMS:

    For optional Akrapovi header pipe only: setup thesleeve togetherwith theflangeandsprings,asshown (Figure 6).

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    Figure 7

    Figure 8

    3. For optional Akrapovi header pipe only: inserttheheadertubeintothesleeve,attachthespringsandtightenthenutstoaspecifiedtorque(Figure 8). WARNING: before tightening the nuts, make sure, that springs pull the header tube all the way into the sleeve use rubber mallet if necessary to tap the connection into place!

    2. For optional Akrapovi header pipe only: installtheassembledsleeve,flangeandspringsontothemotorcycleandhandtightenthetwomarkedstocknuts(Figure 7). WARNING: do not fully tighten the nuts yet! INSTALLATION TIP: use new stock exhaust port gasket.

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    Figure 9

    Figure 10

    4.

    5.

    For optional Akrapovi header pipe only: tightentheheaderpipebracketusingstockbolt,washerandnut(Figure 9).

    For optional Akrapovi header pipe only: tightentherightlowerpartofthecowling(Figure 10).

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    Figure 11

    Figure 12

    7. For Slip-On EC type approval with Akrapovi optional header only: correctlyinstallAkrapovimetalclampontotheAkrapovilinkpipeandinsertthecatalystintothelinkpipeasshown(Figure 12).WARNING: use anti-seize copper paste on bolt threads of the metal clamp!WARNING: make sure that you put the longer part of the catalyst into the link pipe!

    For Slip-On EC type approval only: correctlyinstallAkrapovimetalclampontotheAkrapovilinkpipe,insertthecatalystandtheAkrapovigraphitegasketintothelinkpipeasshown(Figure 11).WARNING: use anti-seize copper paste on bolt threads of the metal clamp!WARNING: make sure that you put the longer part of the catalyst into the link pipe! WARNING: EC type approval IS VALID ONLY WHEN OPTIONAL CATALYTIC CONVERTER IS INSTALLED!

    6.

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    For Slip-On EC type approval only: PositionthemufflercorrectlyandslideitontotheoutletsideofAkrapovilinkpipeandattachthesprings.Alignthemufflerinrespecttothemotorcycle,tightenthemufflersbracketboltusingAkrapovialuminiumcollar(marketonFigure15)andoriginalbolt,washerandnut.Tightenthemetalclamptoaspecifiedtorque(Figure 14, 15).WARNING: make sure, that springs pull the muffler all the way into the link pipe use rubber mallet if necessary to tap the connection into place!

    9.

    Figure 13

    Figure 14

    For Slip-On EC type approval with original or optional Akrapovi header pipe: correctlypositionandslidetheAkrapovilinkpipeontotheoriginalorAkrapoviheaderpipeandhandtightenthemetalclamp(Figure 13).CAUTION: Do not fully tighten the metal clamp yet!

    8.

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    For Slip-On open only: attachonlytheAkrapovimetalclampontothemufflerinlet(donotusethegraphitegasket).For Slip-On open with optional Akrapovi header pipe only: inserttheAkrapovigraphitegasketandattachthemetalclampontothemufflerinletasshown(Figure 16).WARNING: use anti-seize copper paste on bolt threads of the metal clamp!

    10.

    Figure 15

    Figure 16

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    For Slip-On open with original or optional Akrapovi header pipe: positionthemufflercorrectlyandslideitontotheoutletsideoforiginalorAkrapovicheaderpipe.Alignthemufflerinrespecttothemotorcycleandtightenthecarbon-fiberclampusingoriginalbolt,washerandnut.Tightenthemetalclamptoaspecifiedtorque(Figure 18).

    12.

    Figure 17

    For Slip-On open only: correctlypositionthecarbon-fiberclampandslide itontothemuffler-bear inmindtheright offsetofthecarbonfiber-clampviewedfromtherear;checkthepositionoftheyellowstickerontheclamp(Figure 17).WARNING: open the clamp slightly wider than the diameter of the outer sleeve of the muffler do not scrape it along the muffler outer sleeve!

    11.

    Figure 18

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    IT IS NORMAL IF WHITE SMOKE COMES OUT OF THE MUFFLER ON FIRST OPERATION.

    DO NOT STAND BEHIND THE MUFFLER ON FIRST OPERATION. DO NOT USE AUTOMOTIVE WHEEL CLEANERS OR ANY CLEANING PRODUCTS WHICH CONTAIN ACIDIC ADDITIVES TO CLEAN AKRAPOVI EXHAUST SYSTEMS.

    1. Cleanthetitaniumexhaustcomponentswithamulti-purposespraylubricant(WD-40orequivalent),carbonfiberexhaustcomponentswithsoftanddryclothandstainlesssteelcomponentswithsoftclothsprayedwithcontactcleaner,thenwipewithsoftanddrycloth.Achangeinthecoloroftheexhaustsystemisnormalduetothehightemperatures.

    2. Periodicallymakesurealltheboltsandspringsaresufficientlytight.

    WARNING: make sure all the bolts are sufficiently tightened. In case the exhaust system touches thecowling or other parts repeat the adjustment of the exhaust system or contact your authorized dealer.

    MAINTENANCE OF THE AKRAPOVI EXHAUST SYSTEM:

    Final installation:

    WARNING: check vehicle manufacturer manual for tightening torques (for dismounted stock parts)!

    Cleangreasespots:a. Mufflerstainlesssteeloutersleeve:useasoftclothsprayedwithamulti-purposespraylubricant(WD-

    40orequivalent).b. Muffler-carbon-fiberoutersleeve:useasoftdrycloth.c. Mufflercarbon-fiberoutletcap:useasoftdrycloth.d. StainlesssteelheaderpipeandLinkpipe:useasoftclothsprayedwithacontactcleaner,thenwipe

    withasoftdrycloth.

    Cleaningwillpreventspotsfromburningontothesurface.Donotuseaggressivechemicalcleaners,becausetheycandamagethesticker.

  • Sleeve P-RKS300RSS35/1Repack P-RPCK58

    MUFFLER REPAIR KITS

    HONDA CBR 250 R, Partial exhaust system / Slip-ON line / EC Type approval Product code: S-H25SO1-HRSS

    V-TUV018 NOISE REDUCTION INSERT

    WARNING! EC TYPE APPROVAL IS VALID ONLY WHEN OPTIONAL CATALYST IS INSTALLED! WARNING! IN CASE OF COMBINATION WITH OPTIONAL LINK PIPE, MUFFLER EC TYPE APPROVAL IS NOT VALID!

    P-F56 FLANGE P-23 INNER SLEEVE

    H-H25R1 HEADER PIPE

    P-R61 CLAMP

    P-G11 GRAPHITE GASKET

    P-KAT-028 CATALYST - OPTIONAL

    M-HR02702SS/4 MUFFLER

    P-TT45 BELT

    P-TT45 BELT

    V-EC146 END CAP SET

    P-HST2AL STICKER

    H-H25R1/1 OPTIONAL- HEADER PIPE SET

    L-H25SO1LINK PIPE

    P-S1 SPRING

    P-S1 SPRING

    P-S2 SPRING

    P-S2 SPRING

    P-GUV004 RUBBER CAP

    Sleeve P-RKS315ZSS30Repack P-RPCK39

    MUFFLER REPAIR KITS

    PART LISTPcs.DescriptionPart number AkrapovicPos.

    System1Muffler2

    Muffler clamp3Link pipe4Collector5

    Header tube6Bracket7Spring8Bolt9

    Washer10Nut11

    Spacer12Graphite gasket13

    Flange14Inner sleeve15

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    HONDA CBR 250 R, Partial exhaust system / Slip-ON line Product code: S-H25SO1-ZC

    H-H25R1/1 HEADER SET - OPTIONAL

    M-Z04802C MUFFLER

    P-MCCZ4 MUFFLER CLAMP

    P-TT19 BELT

    P-TT19 BELT

    V-EC95 END CAP SET

    P-GUV004 RUBBER CAP

    V-TUV098 NOISE REDUCTION INSERT

    P-R61 CLAMP

    P-S2 SPRING

    P-S2 SPRING

    P-F23 INNER SLEEVEP-56 FLANGE

    COOPER PASTE

    P-VST2AL STICKER

    P-G11 GRAPHITE GASKET

    H-H25R1 HEADER PIPE

    A

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